COMPOSITE FORMED OF CUBIC BORON NITRIDE WITHOUT TI-BASED CERAMIC COMPOUND AND METHOD OF MAKING THEREOF

Abstract

 A cubic boron nitride (cBN)-based composite including about 30 - 65 vol. % cBN, about 3 - 30 vol. % zirconium (Zr)-containing compounds, about 0 - 10 vol. % cobalt-tungsten-borides (Co_xW_yB_z), about 2 - 30 vol. % aluminum oxide (Al₂O₃), about 0.5 - 10 vol. % tungsten borides, and less than or equal to about 5 vol. % aluminum nitride (AIN).

Description

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY

[0001] The present disclosure relates generally to composite materials formed of cubic boron nitride and methods of making and using the same. Specifically, the present disclosure relates to such composite materials that are useful in machining of difficult-to-cut materials.

BACKGROUND

[0002] In the discussion of the background that follows, reference is made to certain structures and/or methods. However, the following references should not be construed as an admission that these structures and/or methods constitute prior art. Applicant expressly reserves the right to demonstrate that such structures and/or methods do not qualify as prior art.

[0003] Cubic boron nitride (cBN) is a super-hard material that is often used to form cBN-based composites for cutting and/or machining applications. Certain ceramic materials, such as alumina (Al₂O₃), titanium nitride (TiN), silicon nitride (Si₃N₄), etc. may be blended with cBN to improve the resistance to chemical wear. However, such ceramic materials may not possess sufficient hardness and/or thermal resistance to perform optimally when machining hard materials. For example, existing cBN-based composites may still exhibit rapid wear, fracture, and/or failure when cutting or machining difficult-to-cut materials, especially heat resistant superalloys. Therefore, there is a need for a better cBN-based composite material with improved properties for cutting and machining difficult-to-cut materials.

SUMMARY

[0004] The present invention comprises cubic boron nitride (cBN)-based composites, cutting tools and methods of forming a cubic boron nitride (cBN)-based composites according to the claims herein. According to certain aspects, a cubic boron nitride (cBN)-based composite is provided including about 30 - 65 vol. % cBN, about 3 - 30 vol. % zirconium (Zr)-containing compounds, about 0 - 10 vol. % cobalt-tungsten-borides (Co_xW_yB_z), about 2 - 30 vol. % aluminum oxide (Al₂O₃), about 0.5 - 10 vol. % tungsten borides, and less than or equal to about 5 vol. % aluminum nitride (AIN).

[0005] Also provided is a method of forming a cubic boron nitride (cBN)-based composite. The method includes mixing powders of a cBN-based formulation for forming the cBN-based composite to form a first mixture. The cBN-based composite includes about 30 - 65 vol. % cBN, about 3 - 30 vol. % zirconium (Zr)-containing compounds, about 0 - 10 vol. % cobalt-tungsten-borides (Co_xW_yB_z), about 2 - 30 vol. % aluminum oxide (Al₂O₃), about 0.5 - 10 vol. % tungsten borides, and less than or equal to about 5 vol. % aluminum nitride (AIN). The method includes drying the first mixture to form a second mixture and loading the second mixture into one or more refractory molds. The method also includes sintering the second mixture at high-pressure-high-temperature conditions.

[0006] Further provided is a cutting tool includes a sintered cubic boron nitride (cBN)-based compact. The cBN-based compact includes about 30 - 65 vol. % cBN, about 3 - 30 vol. % zirconium (Zr)-containing compounds, about 0 - 10 vol. % cobalt-tungsten-borides (Co_xW_yB_z), about 2 - 30 vol. % aluminum oxide (Al₂O₃), about 0.5 - 10 vol. % tungsten borides, and less than or equal to about 5 vol. % aluminum nitride (AIN). The sintered compact is formed by mixing powders of a cBN-based formulation for forming the sintered cBN-based compact to form a first mixture, drying the first mixture to form a second mixture, loading the second mixture into one or more refractory molds, and sintering the second mixture at high-pressure-high temperature conditions to form the sintered compact.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The foregoing summary, as well as the following detailed description of the embodiments, can be better understood when read in conjunction with the appended drawings. It should be understood that the embodiments depicted are not limited to the precise arrangements and instrumentalities shown.

FIG. 1 shows an exemplary process for forming a cBN-based sintered compact or composite;

FIG. 2 shows an XRD spectrum showing phases present in an exemplary cBN-based sintered compact or composite;

FIG. 3 shows an XRD spectrum showing phases present in another exemplary cBN-based sintered compact or composite;

FIG. 4 shows an XRD spectrum showing phases present in another exemplary cBN-based sintered compact or composite; and

FIG. 5 shows an XRD spectrum showing phases present in another exemplary cBN-based sintered compact or composite.

DETAILED DESCRIPTION

[0008] The disclosure relates to composites or sintered compacts formed of cubic boron nitride (cBN) and methods of making and using the same. Specifically, the present disclosure relates to improved cBN-based composite materials that are useful in cutting and machining difficult-to-cut materials, for example, superalloys for applications requiring high strength in high temperature ranges. For example, the cBN-based composite materials (e.g., sintered compacts) disclosed herein may be used for cutting and/or machining nickel-based superalloys (e.g., Inconel 718, Inconel 625), cobalt-based superalloys (e.g., Alloy 188, Haynes 25, Alloy L605), iron-based superalloys (e.g., A286), or any materials of equivalent, inferior, or superior mechanical properties than these superalloys.

[0009] The cBN-based composite materials disclosed herein can include, among other improvements, greater abrasion resistance, toughness, chemical resistance, hardness, and/or hot hardness. These improvements are at least partially attributed to the combination of cBN, cobalt-tungsten-borides (Co_xW_yB_z), tungsten borides (WB, W₂B, W₂B₅, or a combination thereof), alumina (Al₂O₃), and zirconium (Zr)-containing compounds (zirconium dioxide, zirconium nitride, zirconium carbide, zirconium carbo-nitride, zirconium diboride, or a combination thereof) in the proportions disclosed herein. The disclosure also describes methods for forming the cBN-based formulations into sintered compacts, which can be used for cutting or machining of difficult-to-cut materials.

[0010] With the foregoing in mind, Tables 1 and 2 list exemplary compositions of the cBN-based composite materials (e.g., sintered compacts). An exemplary process for forming the cBN-based composite materials is depicted in the flow diagram of FIG. 1. In Tables 1 and 2, all volume percent (vol. %) listed are based on the total vol. % of the cBN-based composite material.

TABLE 1

Materials	Min (vol. %)	Max (vol. %)
cBN	30	65
CoxWyBz	0	15
tungsten borides	0.5	10
Al2O3	2	30
Zr-containing compounds	2	30
AlN	0	5

TABLE 2

Materials	Min (vol. %)	Max (vol. %)
cBN	45	55
CoxWyBz	3	15
tungsten borides	1	3
Al2O3	5	25
Zr-containing compounds	8	15
AlN	0	<1

[0011] The cBN-based composite materials (e.g., sintered compacts) may include about 30 - 65 vol. % cBN, about 40-60 vol. % cBN, about 45-55 vol. % cBN, about 50 vol. % cBN, or about 60 vol. % cBN. Additionally, the cBN-based composite materials may include about 0 - 15 vol. % (e.g., about 0.1 - 15 vol. %) Co_xW_yB_z, about 0 - 10 vol. % (e.g., about 0.1 -10 vol. %) Co_xW_yB_z, about 3-15 vol. % Co_xW_yB_z, about 3 - 12 vol. % Co_xW_yB_z, or about 3 - 8 vol. % Co_xW_yB_z. Further, the cBN-based composite materials may include about 0.5 - 10 vol. % tungsten borides, about 0.5 - 6 vol. % tungsten borides, about 3 - 8 vol. % tungsten borides, or about 1 - 3 vol. % tungsten borides. As provided, the cBN-based composite materials may include about 2 - 30 vol. % Al₂O₃, about 5 - 25 vol. % Al₂O₃, about 2 - 15 vol. % Al₂O₃, about 10 - 20 vol. % Al₂O₃, or about 5 - 10 vol. % Al₂O₃. The cBN-based composite materials may also include about 2 - 30 vol. % Zr-containing compounds, about 5 - 25 vol. % Zr-containing compounds, about 8 - 15 vol. % Zr-containing compounds, or about 3 - 15 vol. % Zr-containing compounds. In addition, the cBN-based composite materials may include less than or equal to about 5 vol. % aluminum nitride (AIN) (e.g., about 0.01 - 5 vol. % AIN, about 0.01 - 4 vol. % AIN, about 0.01 - 3 vol. % AIN, or about 0.01 - 1 vol. % AIN). The tungsten borides disclosed herein may include WB, W₂B, W₂B₅, or a combination thereof. The Zr-containing compounds disclosed herein may include zirconium dioxide (ZrO₂), zirconium nitride (ZrN), zirconium carbide, (ZrC), zirconium carbo-nitride (ZrCN), zirconium diboride (ZrB₂), or a combination thereof. The ZrO₂ can be in cubic phase (c-ZrO₂), monoclinic phase (m-ZrO₂), and/or tetragonal phase.

[0012] FIG. 1 depicts an exemplary process 100 of forming the cBN-based composite materials (e.g., sintered compacts). The exemplary process 100 includes mixing powers of a cBN-based formulation to form a first mixture (step 102). The cBN-based formulation may comprise or consist of one or more powdered formulations including, e.g., a powder comprising or consisting of cBN, a powder comprising or consisting of zirconium, such as a powder comprising zirconium oxide (could be cubic, monoclinic, and/or tetragonal phases), ZrN, ZrC, ZrCN, and/or ZrB₂, a powder comprising or consisting of aluminum, such as a powder comprising Al₂O₃ and/or AIN, a powder comprising or consisting of W, a powder comprising or consisting of Co, a powder comprising or consisting of B, and combinations thereof. Step 102 includes providing powders that can be used to form the cBN-based composite materials disclosed herein (e.g., compositions shown in Tables 1 and 2). The powders can be nano- and/or micron-sized powers, for example, the average particle sizes of the powers of the cBN-based formulation can be in nanometer (nm) or micrometer (µm) ranges, i.e., about 100 nm - 6 µm. Step 102 can include mixing the powders to form a mixture or slurry. The powders can be mixed using any suitable milling or blending techniques (e.g., attribution mill, ball mill, etc.). The powders can be milled or blended in any suitable solvents, for example, ethanol, isopropanol, acetone, methanol, hexane, heptane, or a combination thereof to form the first mixture. The milling conditions (e.g., time, rotation per minute, types of medium or solvent, etc.) can be adjusted or tuned according to the size and/or type of the mill used to achieve desired mixing effects (e.g., powder distribution and uniformity).

[0013] The process 100 can include drying the first mixture to form a second mixture (step 104). The first mixture or slurry formed in step 102 can be dried using any suitable techniques, for example, vacuum dry, air dry, etc., to substantially remove the solvents and/or binders in the first mixture.

[0014] The process 100 can include loading the second mixture into refractory mold(s) (step 106). The refractory mold(s) can be made of any suitable materials, including any suitable refractory metals, for example, tantalum, niobium, molybdenum, etc. Step 106 can include loading the second mixture into the refractory mold and capping with a cemented carbide (WC-Co) disc that fits snugly within the opening of the mold. Step 106 can also include sealing the refractory mold(s) containing the second mixture and/or the WC-Co substrate/disc.

[0015] The process 100 can include sintering the second mixture at high-pressure-high-temperature conditions (step 108). The sealed refractory mold(s) containing the second mixture can be placed in a high-pressure-high-temperature (HPHT) cell and HPHT sintering conditions are applied to form the cBN-based composite materials (e.g., sintered compacts) disclosed herein. Step 108 can include sintering the second mixture at pressures about 5 gigapascal (GPa) - 8 GPa and at temperatures about 1300 - 1600 °C. Step 108 can include sintering the second mixture at a pressure of at least 4 GPa and at a temperature of at least 1100 °C. The cBN-based composite materials (e.g., sintered compacts) can have cBN grain sizes in nanometer or submicron range, for example about 0.1-10 µm, about 0.1-8 µm, about 0.1-6 µm, about 0.1-4 µm, about 0.1-2 µm, about 2-4 µm, about 0.1-1 µm, about 0.8-1.2 µm, or about 1 µm.

[0016] The cBN-based composite materials (e.g., sintered compacts) formed according to the process 100 can be used for cutting or machining difficult-to-cut materials. For example, the cBN-based composite materials formed according to process 100 can be formed into cutting tools for cutting and/or machining high-strength superalloys, including nickel-based superalloys (e.g., Inconel 718, Inconel 625), cobalt-based superalloys (e.g., Alloy 188, Haynes 25, Alloy L605), iron-based superalloys (e.g., A286), or any materials of equivalent, inferior, or superior mechanical properties than these superalloys.

[0017] Without wishing to be bound by any particular theory, it is believed that the compositions and phases of the cBN-based composite materials (e.g., sintered compacts) disclosed herein can contribute to improving the abrasion resistance, toughness, chemical resistance, hardness, hot hardness, or a combination thereof, thereby improving the cutting and machining capabilities. Table 3 shows exemplary cutting performances using cutting tools made of the cBN-based composite materials (e.g., sintered compacts) disclosed herein.

Table 3

Sample	cBN		Major phases					Cut distance (km)
	grain size (µm)	vol. %	Al	Zr	W	Co	Ti
Sample 1	2-4	60	Al2O3, AIN	ZrB2	WB, W2B	none	none	0.8
Sample 2	0-2	60	Al2O3	ZrCN	W2B, W2B5, CoW2B2, CoWB	CoW2B2, CoWB	none	1.0
Sample 3	0-1	50	Al2O3	ZrB2, ZrCN	WB, CoW2B2, CoWB	CoW2B2, CoWB	none	1.3
Sample 4	0-1	50	Al2O3	ZrCN	WB, WC, CoW2B2, CoWB	CoW2B2, CoWB	none	1.0
Sample 5	1	50	Al2O3	none	WC	none	TiCN, TiN	0.7

[0018] In the illustrated examples, Samples 1-5 represent cutting tool made of the cBN-based composite materials (e.g., the sintered compacts) formed based on compositions shown in Tables 1 and 2 and process 100 described in FIG. 1. The cutting tests were performed on Inconel 718 at a speed of 350 meters per minute (m/min) and a feed rate of 0.15 millimeter per revolution (mm/revolution) with coolant being continuously applied to the cutting interface. The cutting tests were performed for a predetermined flank wear of 0.25 mm for Samples 1-5. The cut distances in kilometer (km) at the end of tool life are shown in the right most column in Table 3.

[0019] Sample 1 and Sample 2 both contain cBN about 60 vol. %, an Al-containing phase or compound (Al₂O₃ and/or AIN), a Zr-containing phase or compound (ZrCN and/or ZrB₂), and a W-containing phase or compound (WB, W₂B, W₂B₅, CoW₂B₂, and/or CoWB), and both do not contain a titanium (Ti)-containing phase or compound. A difference between Sample 1 and Sample 2 is that Sample 2 contains W₂B₅ and Co_xW_yB_z (CoW₂B₂, CoW₃B₃, and/or CoWB) whereas Sample 1 does not, and Sample 2 has a slightly smaller sintered grain size. The cut distances are 0.8 km for Sample 1 and 1.0 km for Sample 2. Sample 3 and Sample 4 both contain cBN about 50 vol. %, an Al-containing phase or compound (Al₂O₃), a Zr-containing phase or compound (ZrCN and/or ZrB₂), a W-containing phase or compound (WB, WC, CoW₂B₂, CoW₃B₃ and/or CoWB), and a Co-containing phase or compound (CoW₂B₂, CoW₃B₃, and/or CoWB), and both do not contain a Ti-containing phase or compound. A difference between Sample 3 and Sample 4 is that Sample 3 contains ZrB₂ whereas Sample 4 does not, and Sample 4 contains WC whereas Sample 3 does not. The cut distances are 1.3 km for Sample 3 and 1.0 km for Sample 4. Although Sample 5 also contains about 50 vol. % cBN, Sample 5 is different from Samples 1-4 in that Sample 5 contains a Ti-containing phase or compound (titanium carbo-nitride (TiCN) and/or titanium nitride (TiN)), and does not contain a Zr-containing phase or compound and Co_xW_yB_z. The cut distances for Sample 5 is 0.7 km.

[0020] Without wishing to be bound by any particular theory, it is believed that the presence of Al₂O₃, the presence of Co_xW_yB_z, the presence of tungsten borides, and the presence of the Zr-containing compounds can contribute to improved cutting capabilities. It is also believed that cBN-based composite materials with relatively lower cBN contents (e.g., about 50 vol. %, about 45 - 55 vol. %) can have better cutting capabilities than that with relatively higher cBN contents (e.g., about 60 vol. %, about 65 vol. %). It is also believed that in some embodiments, the cBN-based composite materials including Al₂O₃, Co_xW_yB_z, tungsten borides, and Zr-containing compounds, and free or substantially free of Ti-containing compounds (e.g., titanium nitride (TiN), titanium carbo-nitride (TiCN), titanium carbide (TiC), titanium-carbo-oxinitride (TiCON), titanium-oxinitride (TiNO), or a combination thereof), can have better cutting capabilities than that with titanium (Ti)-containing binders but without tungsten borides and/or Co_xW_yB_z..

[0021] Without wishing to be bound by any particular theory, it is believed that the specific combinations and/or exclusions of certain crystalline phases can contribute to the enhanced cutting capabilities of the cBN-based composite materials (e.g., sintered compacts) disclosed herein. For example, the Co_xW_yB_z are present in the cBN-based composite materials (e.g., sintered compacts) as crystalline phases, thereby contributing to the improved cutting capabilities. For example, the Co_xW_yB_z may be present as one or more of crystalline CoWB, crystalline CoW₂B₂, and/or crystalline CoW₃B₃. For example, the Zr-containing compounds are present in the cBN-based composite materials (e.g., sintered compacts) as ZrB₂ and/or ZrCN, thereby contribute to the improved cutting capabilities. For example, the tungsten borides (such as WB, W₂B, and W₂B₅) are present in the cBN-based composite materials (e.g., sintered compacts), thereby contributing to the improved cutting capabilities.

[0022] In some embodiments, the cBN-based composite materials (e.g., sintered compacts) disclosed herein can be substantially free of or exclude aluminum nitride (AIN) and/or aluminum diboride (AlB₂). In some embodiments, the cBN-based composite materials (e.g., sintered compacts) disclosed herein can be substantially free of or exclude titanium (Ti)-containing compounds or phases (e.g., TiCN, TiN). In some embodiments, the cBN-based composite materials (e.g., sintered compacts) disclosed herein can include a very low content or negligible amount of AIN, e.g., less than 1 vol. % AlN. In some embodiments, the cBN-based composite materials (e.g., sintered compacts) disclosed herein can include Al₂O₃ and Zr-containing compounds. In some embodiments, the cBN-based composite materials (e.g., sintered compacts) disclosed herein can be substantially free of or exclude W₂C₂₁B₆.

[0023] X-ray diffraction (XRD) can be performed on the cBN-based composite materials (e.g., sintered compacts) disclosed herein to identify the phases present. FIGS. 2, 3, 4, and 5 show XRD spectra from Sample 1, Sample 2, Sample 3, and Sample 4, respectively. The XRD spectra of FIG. 2 verifies that Sample 1 contains cBN and other major phases including Al₂O₃, AIN, ZrB₂, WB, and W₂B. The XRD spectra of FIG. 3 verifies that Sample 2 contains cBN and other major phases including Al₂O₃, ZrCN, W₂B, W₂B₅, CoWB, and CoW₂B₂. As also shown in the XRD spectra of FIG. 3, CoW₃B₃ is present. The XRD spectra of FIG. 4 verifies that Sample 3 contains cBN and other major phases including Al₂O₃, ZrB₂, ZrCN, WB, CoW₂B₂, and CoWB. The XRD spectra of FIG. 5 verifies that Sample 4 contains cBN and other major phases including Al₂O₃, ZrCN, WB, WC, CoW₂B₂, and CoWB. As also shown in the XRD spectra of FIG. 5, CoW₃B₃ is present.

[0024] Unless defined otherwise all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently described subject matter pertains.

[0025] Where a range of values is provided, for example, concentration ranges, percentage ranges, or ratio ranges, it is understood that each intervening value, to the tenth of the unit of the lower limit, unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the described subject matter. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and such embodiments are also encompassed within the described subject matter, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the described subject matter.

[0026] It should be understood that the terms "a" and "an" as used above and elsewhere herein refer to "one or more" of the enumerated components. It will be clear to one of ordinary skill in the art that the use of the singular includes the plural unless specifically stated otherwise. Therefore, the terms "a," "an" and "at least one" are used interchangeably in this application.

[0027] Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as size, weight, reaction conditions and so forth used in the specification and claims are to the understood as being modified in all instances by the term "about". As throughout the application, the term "about" may mean plus or minus 10% of the numerical value of the number with which it is being used; therefore, about 50% may mean in the range of 45%-55%. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0028] Throughout the application, descriptions of various embodiments use "comprising" language; however, it will be understood by one of skill in the art, that in some instances, an embodiment can alternatively be described using the language "consisting essentially of or "consisting of."

[0029] While reference has been made to specific embodiments, it is apparent that other embodiments and variations can be devised by others skilled in the art without departing from their spirit and scope. The appended claims are intended to be construed to include all such embodiments and equivalent variations.

[0030] The following numbered embodiments are encompassed by the present invention. These embodiments include:

Embodiment 1. A cubic boron nitride (cBN)-based composite, comprising:

about 30 - 65 vol. % cBN;

about 3 - 30 vol. % zirconium (Zr)-containing compounds;

about 0 - 10 vol. % cobalt-tungsten-borides (Co_xW_yB_z);

about 2 - 30 vol. % aluminum oxide (Al₂O₃);

about 0.5 - 10 vol. % tungsten borides; and

less than or equal to about 5 vol. % aluminum nitride (AIN).

Embodiment 2. The cBN-based composite of embodiment 1, comprising about 45 - 55 vol. % cBN, about 8 - 15 vol. % Zr-containing compounds, about 3 - 8 vol. % Co_xW_yB_z, about 5 - 25 vol. % Al₂O₃, about 3 - 8 vol. % tungsten borides, and less than 1 vol. % AIN.

Embodiment 3. The cBN-based composite of embodiment 1 excludes Ti-containing compounds.

Embodiment 4. The cBN-based composite of embodiment 1, wherein the tungsten borides comprise WB, W₂B, W₂B₅, or a combination thereof.

Embodiment 5. The cBN-based composite of embodiment 1, wherein the Co_xW_yB_z comprises crystalline CoWB, crystalline CoW₂B₂, crystalline CoW₃B₃, or a combination thereof.

Embodiment 6. The cBN-based composite of embodiment 1, wherein the Co_xW_yB_z excludes W₂Co₂₁B₆.

Embodiment 7. The cBN-based composite of embodiment 1 excludes aluminum nitride (AIN), aluminum diboride (AlB₂), or both.

Embodiment 8. The cBN-based composite of embodiment 1, wherein the Zr-containing compounds comprise zirconium nitride (ZrN), zirconium carbide (ZrC), zirconium carbo-nitride (ZrCN), zirconium diboride (ZrB₂), zirconium dioxide (ZrO₂), or a combination thereof.

Embodiment 9. A cutting tool for cutting superalloys comprising Inconel 718, Inconel 625, alloy 188, Haynes 25, Alloy L605, and/or A 286, comprising the cBN-based composite of embodiment 1.

Embodiment 10. The cBN-based composite of embodiment 1 having a grain size of about 0.1-4 micrometer (µm).

Embodiment 11. A method of forming a cubic boron nitride (cBN)-based composite, comprising:

mixing powders of a cBN-based formulation for forming the cBN-based composite to form a first mixture, wherein the cBN-based composite comprises:

about 30 - 65 vol. % cBN;

about 3 - 30 vol. % zirconium (Zr)-containing compounds;

about 0 - 10 vol. % cobalt-tungsten-borides (Co_xW_yB_z);

about 2 - 30 vol. % aluminum oxide (Al₂O₃);

about 0.5 - 10 vol. % tungsten borides; and

less than or equal to about 5 vol. % aluminum nitride (AIN);

drying the first mixture to form a second mixture;

loading the second mixture into one or more refractory molds; and sintering the second mixture at high-pressure-high-temperature conditions.

Embodiment 12. The method of embodiment 11, comprising mixing the powders of the cBN-based formulation with one or more solvents comprising ethanol, isopropanol, acetone, methanol, hexane, heptane, or a combination thereof to form the first mixture.

Embodiment 13. The method of embodiment 11, wherein drying the first mixture comprises vacuum drying the first mixture.

Embodiment 14. The method of embodiment 11, wherein loading the second mixture comprises disposing the second mixture and a cemented carbide (WC-Co) substrate or disc in the one or more refractory molds.

Embodiment 15. The method of embodiment 11, comprises sintering the second mixture at a pressure of at least 4 gigapascal (GPa) and at a temperature of at least 1100 °C.

Embodiment 16. A cutting tool, comprising:

a sintered cubic boron nitride (cBN)-based compact comprising:

about 30 - 65 vol. % cBN;

about 3 - 30 vol. % zirconium (Zr)-containing compounds;

about 0 - 10 vol. % cobalt-tungsten-borides (Co_xW_yB_z);

about 2 - 30 vol. % aluminum oxide (Al₂O₃);

about 0.5 - 10 vol. % tungsten borides; and

less than or equal to about 5 vol. % aluminum nitride (AIN), wherein the sintered compact is formed by:

mixing powders of a cBN-based formulation for forming the sintered cBN-based compact to form a first mixture;

drying the first mixture to form a second mixture;

loading the second mixture into one or more refractory molds; and

sintering the second mixture at high-pressure-high temperature conditions to form the sintered compact.

Embodiment 17. The cutting tool of embodiment 16, wherein the sintered cBN-based compact comprises about 45 - 55 vol. % cBN, about 8 - 15 vol. % Zr-containing compounds, about 3 - 8 vol. % Co_xW_yB_z, about 5 - 25 vol. % Al₂O₃, about 3 - 8 vol. % tungsten borides, and less than 1 vol. % AIN.

Embodiment 18. The cutting tool of embodiment 16, wherein the sintered cBN-based compact excludes W₂Co₂₁B₆, aluminum nitride (AIN), aluminum diboride (AlB₂), or a combination thereof.

Embodiment 19. The cutting tool of embodiment 16, wherein the Zr-containing compounds comprise zirconium nitride (ZrN), zirconium carbide (ZrC), zirconium carbo-nitride (ZrCN), zirconium diboride (ZrB₂), zirconium dioxide (ZrO₂), or a combination thereof.

Embodiment 20. The cutting tool of embodiment 16, wherein the sintered cBN-based compact excludes Ti-containing compounds.

Claims

1. A cubic boron nitride (cBN)-based composite, comprising:

30 - 65 vol. % cBN;

3 - 30 vol. % zirconium (Zr)-containing compounds comprising any one or a combination of zirconium nitride (ZrN), zirconium carbide (ZrC), zirconium dioxide (ZrO₂);

0 - 10 vol. % cobalt-tungsten-borides (Co_xW_yB_z);

2 - 30 vol. % aluminum oxide (Al₂O₃);

0.5 - 10 vol. % tungsten borides; and

less than or equal to 5 vol. % aluminum nitride (AIN).

2. The cBN-based composite of claim 1, comprising 45 - 55 vol. % cBN8 - 15 vol. % Zr-containing compounds, 3 - 8 vol. % Co_xW_yB_z, 5 - 25 vol. % Al₂O₃, 3 - 8 vol. % tungsten borides, and less than 1 vol. % AIN.

3. The cBN-based composite of claim 1 excludes Ti-containing compounds.

4. The cBN-based composite of claim 1, wherein the tungsten borides comprise WB, W₂B, W₂B₅, or a combination thereof.

5. The cBN-based composite of claim 1, wherein the Co_xW_yB_z comprises crystalline CoWB, crystalline CoW₂B₂, crystalline CoW₃B₃, or a combination thereof.

6. The cBN-based composite of claim 1, wherein the Co_xW_yB_z excludes W₂Co₂₁B₆.

7. The cBN-based composite of claim 1 wherein the cBN-based composite excludes aluminum nitride (AIN), aluminum diboride (AlB₂), or both.

8. The cBN-based composite of claim 1, wherein the Zr-containing compounds further comprise zirconium carbo-nitride (ZrCN), zirconium diboride (ZrB₂), or a combination thereof.

9. A cutting tool for cutting superalloys including nickel-based superalloys, cobalt-based superalloys and iron-based superalloys comprising the cBN-based composite of claim 1.

10. The cBN-based composite of claim 1 having a grain size of about 0.1 µm to 4 µm.

11. A method of forming a cubic boron nitride (cBN)-based composite, comprising:

mixing powders of a cBN-based formulation for forming the cBN-based composite of claim 1 to form a first mixture;

drying the first mixture to form a second mixture;

loading the second mixture into one or more refractory molds; and

sintering the second mixture at a pressure of at least 4 gigapascal (GPa) and at a temperature of at least 1100°C.

12. The method of claim 11, comprising mixing the powders of the cBN-based formulation with one or more solvents comprising ethanol, isopropanol, acetone, methanol, hexane, heptane, or a combination thereof to form the first mixture.

13. The method of claim 11, wherein drying the first mixture comprises vacuum drying the first mixture.

14. The method of claim 11, wherein loading the second mixture comprises disposing the second mixture and a cemented carbide (WC-Co) substrate or disc in the one or more refractory molds.

Drawing